Armature fault analyzer



July 13, 1954 c. R. REID 2,683,860

ARMATURE FAULT ANALYZER Filed March 6, 1952 4 Sheets-Sheet 1 GE N LQATOQ. 1

INVENTOR. Carl R. 1201' a BY WAX/Emma ATTORNEY.

July 13, 1954 Q R R 2,683,860

ARMATURE FAULT ANALYZER Filed March 6, 1952 4 Sheets-Sheet 2 :2 INVENTOR.

(ax-1 Q Reid ATTORNEY.

y 3, 1954 c. R. REID ARMATURE FAULT ANALYZER 4 Sheets-Sheet 5 Filed March 6, 1952 INVENTOR ATTORNEY.

cal-1 12.129

ME V3 July 13, 1954 c. R. REID 2,683,860

ARMATURE FAULT ANALYZER Filed March 6, 1952 4 Sheets-Sheet 4 IN VEN TOR. Carl [2. Reid ATTORNEY.

Patented July 13, 1954 UNITED S'l OFFICE ARMATURE FAULT ANALYZER Carl R. Reid, Akron, Ohio, assignor to The Hoover Company, North Canton, Ohio, a corporation of Ohio 20 Claims. 1

My invention relates an apparatus for subjecting armatures of electric motors to a test which will determine the existence of any one of a multitude of faults introdduced into armatures during the manufacturing process.

The subject matter of this application is related to the testing apparatus disclosed in my prior application, Serial No. 246,204 filed September 12, 1951, for Electrical Coil Testing Apparatus. The apparatus disclosed in the aforesaid application is particularly designed to detect the presence of a short circuit in the electrical system of the armature and it is preferable that an armature to be tested on the type of apparatus disclosed in the instant application be first tested to insure the absence of a short circuit.

In particular, it is an object of the present invention to provide a fault analyzing apparatus by which each individual coil of a motor armature is subjected to a test which will selectively indicate the existence of an open circuit, a deficient number of turns in any coil, a surplus number of turns in any coil or an incorrect connection of any coil and will perform the foregoing in a reliable manner requiring but a very small span of time to test a complete armature.

It is a further object of my present invention to provide a motor armature testing apparatus in which the armature to be tested is subjected to a standardized, high frequency magnetic field to induce high frequency voltage in the armature Winding and in which the voltage level of the current induced in the armature is carefully measured and utilized to reveal the existence of particular types of faults and their location in the armature.

Other objects and advantages of the invention will become apparent as the description proceeds when taken in connection with the accompanying drawing, in which:

Figure 1 is a schematic representation of an apparatus embodying my invention;

Figure 2 is a wiring diagram of an electronic mechanism for segregating the informative and non-informative portions of the voltage induced in each coil of a test armature and conditioning the same to operate a detecting and indicating mechanism;

Figure 3 is a schematic wiring diagram of a detecting and alarm signalling apparatus which is driven by the apparatus of Figure 2;

Figure 4 is a diagrammatic representation of voltage conditions existing between two adjacent commutator bars under normal and armature fault conditions;

Figure 5 is a representation of various transformations imparted to the signal structure of Figure 4 to facilitate proper detection of armature conditions;

Figure 6 is a representation of the charge impressed upon a portion of the signal shown in Figure 4 to effect a proper timing of certain portions of the apparatus;

Figure 7 is a representation of transformations imparted to the final signal shown in Figure 5 for the purpose of selecting the proper alarm signalling mechanism; and

Figure 8 is a diagram representing the manner in which two closely related types of armature faults are distinguished from each other.

Before describing my invention in detail, the general scheme of operation will be described with particular reference to Figures 4 and 5. In the present instance, it is assumed that an armature to be tested has previously passed a short circuit test and is normal in that particular. Even if the armature is free of short circuits, it may still fall into five distinct categories which are: ac ceptably normal, hereinafter designated as N, open circuited, hereinafter designated as O-C, having a number of turns in one coil below an acceptable minimum, hereinafter designated as D-T, having a surplus number of turns in one coil over and above an acceptable maximum, hereinafter designated as S-T, or having the connections to one armature coil reversed, hereinafter referred to as I-C. As a practical matter, it is highly unlikely that a particular armature will be affected with more than a single one of the four fault conditions immediately above identified and the discussion herein assumes that no such conditions exist, but such remotely possible mutiple fault conditions do not result in the acceptance of a faulty armature as one fault will be detected.

In general, I propose to rotate the armature to be tested in a standard magnetic field which is energized by an audio-frequency current. For purposes of illustration herein, the armature will be assumed to have twenty-four commutator bars and twenty-four armature coils. The armature will be assumed to rotate at the rate of sixty R. P. M. or one revolution a second and the audiofrequency field will be assumed to have a frequency of twenty-four hundred cycles a second. An armature rotating in such a field will have voltage generated in the coils thereof proportional to the space position of the coil in question in reference to the magnetic axis of the field and roughly proportional to the number of turns in that coil. A pair of prods engage the commutator in position to contact adjacent commutator bars. The voltage between adjacent commutator bars, hereinafter referred to as the prod signal, will be proportional to the condition of the coil connected to such bars and will reflect the existence of any of the above mentioned types of de ficiency or errors of manufacture. The figures of Figure 4 represent somewhat idealized prod signals produced by a normal armature and armatures having the above mentioned winding faults. Each prod signal block of Figure 4 is labelled in accordance with the type of armature coil which it represents. It is to be noted in this connection that the generally rectangular blocks of Figure 4, representing prod signals, are the envelopes of the prod signals as the voltage actually picked up by the prods is of the same frequency as the energizing field. It is also of importance in this connection to note that the shape of the envelopes of Figure 4 assumes absolutely perfect cormnutating condition and the complete absence of transient currents. The legends ii and t4 in each case represent respectively the time at which both prods make contact with a pair of adjacent commutator bars and the time at which contact is lost with a pair of adjacent commutator bars. The time period ii to fl is hereinafter referred to as the bar period. The time ii to 131 during which the prods ride the commutator insulating segments is hereinafter called a segment period. These time periods vary somewhat ue to normal inaccuracies in production commutators and to imperfections in commutating action. Additionally, the value of the prod signal at and closely adjacent to the times represented as t1 and 154 in Figure 4 is invariably subject to unpredictable transient variations which are completely uninformative with respect to the condition of the particular coil to which connection is made. For this reason, most of the prod signal is discarded insofar as it is utilized for purposes of determining coil conditions. Only that portion thereof labelled t2 to ta is actually utilized, by means to be described hereinafter, for

the purpose of determining coil conditions. During the short mid-bar period, represented by the time is to is, transient conditions have disappeared, commutating conditions are steady, and the prod signal truly represents coil conditions.

The prod signal itself is unsuitable for direct interpretation and detection in terms of coil conditions. Consequently the signals, such as those represented by Figure 4, are fed to an electronic device herein referred to as a shaper, which acts in conjunction with a timing device to segregate the informative portion of the prod signal and to convert the same into a wave form which sharply differentiates various types of prod signals at the time t3. The output of the shaper and timing facility is represented by the extreme right hand family of voltage wave forms of Figure 5, each of which is labelled to indicate the armature coil condition which it represents. The significant characteristic of this wave form is a very abrupt rise in voltage at the time is followed by an exponential deca thereof, giving a roughly triangular wave form. It is also highly important to note that the acceptably normal voltage is a mid-value and that D-T and -0 conditions are less than normal. The S-T and 1-0 wave forms can be utilized directly to indicate their presence through voltage level sensitive circuits. This is not, however, possible with the D-T and 0-0 currents, as they are lower than the normal voltage.

4 For this reason, the output of the shaper and timer facility is supplied to a pair of detecting devices which will in effect reject all but the D-T and O=C type signals and will then introduce a delay between the two in reference to time and convert the same into a form which can be utilized to energize suitable alarms. In addition to the foregoing general system, the apparatus includes an arrangement by which the existence of any one of the above identified faults immediately stops the apparatus and energizes a suitable indicating alarm which informs the operator of the type of fault which has been detected. Furthermore, the apparatus will, in general, locate the particular armature coil containing the fault which is indicated.

Referring now to the drawing in detail and first to Figure 1 thereof, the reference character I indicates a test armature having the usual commutator 2. The shaft 3 of the armature is rotatably supported in bearing blocks 4 positioned on opposite sides of a standardized field structure 5 provided with an energizing coil L. The coil L connects to a conductor 8 extending to the secondary of a transformer it, the primary of which is energized by an audio-frequency generator [1. The coils of the armature I are subjected to a high frequency field by the coil L which induces a voltage therein proportional to the intensity of the field, the instantaneous position of any particular coil in the field and the condition of the coil.

The motor shaft 3 is detachably engaged in chuck "i carried by an extended shaft 8 projecting from a combined drive motor and gear reduction mechanism 9. The shaft 8 also carries a brake drum iii adapted to be engaged by a brake shoe H which is set by a spring [2. A solenoid I3 is arranged to release the brake II when the solenoid is energized.

One line of the power supply line 14 is connected to a single pole double throw cam switch 15 biased to close the circuit normally through one of the poles. The normally closed circuit pole of the cam switch 15 is connected to the solenoid l3 and to the drive motor 9 through a normally closed manual switch 9a. A normally open push-button switch I8 is bridged across the normally closed circuit contact of the switch I5 for the purpose of energizing the motor when the circuit through the switch [5 is interrupted. The normally open contact to the switch 15 is connected to an indicating lam H] which connects to the other supply line I4. As shown in Figure 1, the motor and brake solenoid I3 are parallel connected and are connected to the other side of the supply line [4 through four serially connected switches 28, 2i, 22 and 23. Whenever a fault is detected in the test armature, in a manner to be described hereinafter, one of this group of switches is actuated to the open circuit position which de-energizes the motor and sets the brake to stop rotation of the armature. The solenoid i3 is also connected to the supply lines M by a normally open double pole switch 13a to energize the solenoid independently of other switching arrangements.

Rotation of the shaft 8 at sixty R. P. M. or one revolution per second has been found to be quite satisfactory for most commercial types of motor armatures. One complete revolution of the armature, requiring one second, is all that is required for a complete test thereof. It is, however, desirable to rotate the armature somewhat more than one revolution in order to insure steady state conditions during the actual testing period. For this reason, the present apparatus is disclosed as being set up to give the armature one and one half complete revolutions provided no fault is detected. For this purpose, a cam is driven by gears 25 from the shaft 8 for actuating the cam switch l5 to ole-energize the motor 9 and solenoid l3 and to energize the lamp is. The gear ratio is such that the switch will be actuated after one and a half complete revolutions of the shaft 8. In starting the motor, the switch i8 is momentarily closed for a period of time suflicient to allow the cam 25 to clear the cam switch [5 after which the push button 18 may be released and the motor will continue rotating the armature for one and a half revolutions.

As each coil of the armature l moves into the position in which it is in maximum inductive relation to the field produced by the coil L, the commutator bars connected to such coil move into contact with a pair of commutator contacting prods 2i and 28 which are carried by a handle structure 29 pivotally supported upon a suitable standard 3%. As shown in Figure l, the handle 29 is in its raised position in which the prods 2'! and 23 are removed from contact with the commutator 2. When the handle 2E9 is lowered, that is, rotated in a clockwise direction as viewed in Figure l, the prods 2? and 22 will rest upon the commutator 2 to pick up currents induced in individual coils thereof. The spacing between the prods 27 and 28 is of importance in relation to the total span of two adjacent commutator bars, that is, those bars which are connected to the opposite ends of an individual coil in the armature I. It is imperative that the prod spacing positively prevent the possibility of establishing contact with two nonadjacent commutator oars. On the other hand, it is desirable to space the prods sufliciently to give an appreciable time period in which the prods are contacting adjacent commutator bars. For this purpose, it has been found that an angular spacing of the bars equal to 360 divided by the number of commutator bars is a satisfactory spacing, though a somewhat wider or narrower spacing can usually be accommodated if desired. In any event, the angular displacement between the far edges of the two prods must not be greater than the minimum extent of a single commutator bar plus two insulating segments. In addition to the foregoing, the span of the prods should be slightly greater than the insulation span in the commutator under test to insure smooth riding of the prods from bar to bar as the armature is rotated but otherwise narrow to provide maximum time of smooth contact between the prods and each pair of commutator bars.

The signal induced in each armature coil as it comes into the position in which it is connected to the prods 21 and 23 is applied by the conductor 32 to a shaper unit 3! to which is connected a timer 33. The elements will be described in detail hereinafter. For the present, it is sufiicient to note that the timer and shaper cooperate to reject all of the prod signal except that portion between the timer period labelled Q to t3 in Figure 4. The signal occurring in this time period is truly proportional to the condition of the armature coil being tested. The shaper and timer output wave, final right hand form of Figure 5, is applied directly to the S-T and. I-C alarms, 35 and 36, respectively, which are 6. gated so as not to be'activated by voltage peaks lower than the value indicated by ST and 1-0 in the final wave form of Figure 5. If such voltage peaks are applied to these elements, the appropriate circuit is energized and the switch 2i or 2! respectively, is opened to de-energize the motor and set the brake ll. Such direct gating cannot be used for 0-0 and D--T conditions as these-voltage peaks are less than the normally acceptable range. Therefore, the shaper output is also applied to the elements 3? and 38 labelled O-C detector and D-T detector which energize the 0-0 alarm 39 or D-T alarm 49, respectively, if the elements 31 and 38 receive voltage having peaks indicated by D-T and O-C in the final wave form of Figure 5. In any event, whichever alarm is energized is also operative to open the associated motor control switch to terminate the testing operation. Since the motor control and brake solenoids are designed to act very quickly, the armature generally will be stopped with the prods 2! and 28 resting upon the commutator bars connected to the particular armature coil found to have a fault. In normal production procedure, this latter feature generally will be of no particular interest as the existence of a fault will necessitate rejection of the armature in any event. However, in analysis of particular test armatures and in checking upon the performance of winding machinery and operators, it is frequently desirable to know not only the nature of the fault but its particular location in an unsatisfactory armature.

In the case of a faulty armature, the test apparatus will be stopped with the cam 25 in some angular position in which it does not engage the switch l5. As soon as a fault is indicated, the operator applies a suitable marking to the commutator bars upon which the prods 2'! and 28 are resting if that information is desired. The prod support 29 is then rotated to the position of Figure l which removes the prods from engagement with the commutator. A normally open push switch 4.2 is connected in shunt with the series connected switches 29 to 23 inclusive; consequently, the motor and solenoid 43 are energized when the switch 42 is held closed by the operator regardless of the condition of the switches 28 to 23, and motor rotation continues until the motor and solenoid are de-energized when the cam 25 opens the switch i5.

Once a fault has been indicated, the switch associated with that fault indicator remains open and the alarm remains in alarm condition. In order to reset the system, it is necessary to interrupt the plate voltage supply to the alarm systom 35, 36, 39 and 4B. These alarm systems are applied with a regulated plate voltage, for example, 300 volts, from the supply line designated 300R through a normally closed cam switch 44. The cam switch 44 is moved to the open circuit position by a cam 45 driven by a pair of gears 45 from the shaft 8. The time period of one rotation of the cam 45 is the same as that for the cam 25, and it is arranged to open the switch 44 at the time the switch it is open. The cam 45 has a greater angular extent than the cam 25 in order to delay the application of plate voltage to the alarm system for a short period after the motor is energized at the start of a testing operation to prevent false indication due to transients which may occur at the very beginning of a testing operation. Since the armature is rotated one and a half revolutions 7 for a complete test, this delay period does not interfere with the operation of the device, as every coil will be subjected to a full test in any event.

As the arm 29 rotates to the position of Figure 1, the cam 4! carried thereby actuates 2. normally closed circuit switch 43 to open circuit position. The switch 43 is for the purpose of deenergizing the A-F generator l1 when the prod carrying arm 29 is raised to remove the prods from the commutator. With the A-F generator I! de-energized, no voltage is induced in the armature l and it is perfectly safe to remove the same from the chuck 1 and bearings 4 as the operator desires. As shown here, the switches 43 and 44 remove plate voltage from the A-F generator and fault alarms; however, the switches may operate through relays if desired.

Referring to Figure 2, the prod signal conductor 32 connects to the grid of an amplifying triode 5B in the shaper 3|. The prod signal is developed across the parallel connected resistors 5| and 52 which are grounded. If an open circuit armature coil is in prod position, the prods are connected by a comparatively high impedance circuit consisting of the remaining armature coils in series. The value of the resistor is chosen to permit a current flow through this high impedance path sufficient to produce an impedance drop of approximately 50% of the prod voltage for a normal coil. If the armature contains more than one O-C coils, the prod signal voltage will be zero which will produce an -0 alarm as explained hereinafter. If the armature coil in prod position contains a gross deficiency of turns, the prod signal voltage will be in the O-C range and the tester will so indicate. Jlanual means are provided to distinguish this condition if desired consisting of a normally closed switch 53. When the switch 53 is opened, resistor is disconnected and high resistor 52 only is in the prod circuit. The resistor 52 prevents significant current flow through the armature; hence an open circuit coil in prod position under these conditions will result in a prod signal of practically normal value, whereas a coil having a gross deficiency of turns will still produce a low value prod signal.

The cathode of the triode 50 is grounded through a resistor 58 and the anode is connected to the plus 308R service through serially connected resistors 56 and 51 which connect at their junction to grounded condenser 55. The condenser 55 and resistor 55 constitute a decoupling filter to isolate the plus 309R service from the triode 58 to minimize the effect of this element on other parts connected to the plus 3008. service. The variable resistor 51, triode 5!] and resistor 58 form a degenerative stiffening amplifier for the prod signal. The output of the amplifier is developed across a pair of parallel connected impedances of opposite polarity sense consisting of a condenser 59 and oppositely connected diodes 60 and 6! having their anodes and cathodes, respectively, grounded through integrating filters 54 and 62, respectively. The identical filters 54 and 62 each consist of a resistor and a condenser connected in parallel. The condenser 59 has a large capacity and is a current integrating member to avoid cumulative D. C. component in the output of the triode 50 as the voltage level of this output is used to determine coil condition. The negative portion or" the output of the triode .50 is passed by the diode 60 and the voltage across the filter 54 is applied to the timer 33 as described hereinafter. The value of the filters 54 and 62 is primarily determined by the need to approach a D. C. voltage across the filter resistors, but the filter time constants must permit voltage decay substantially to zero when the prods engage insulating segments on the commutator; i. e. time u to $1. The output, cathode to ground, voltage of the diode 6! is represented by the line 63 of Figure 5. This voltage, and all voltage conditions of Figures 5 to 7, are indicated by a dashed line to ground with the appropriate reference character applied to the schematic diagrams of Figures 2 and 3.

The signal voltage 63 is compared to a standard reference voltage for purposes of enhancing and clearly pointing out deviations thereof from an acceptable normal condition. For this purpose, the secondary of the transformer I6 is shown as having a grounded center point with the energizing coil L fed from one end thereof and the cathode of referencing diode 64 fed from the other end thereof. Thus the instantaneous voltage on the cathode of the diode 54 is always equal and opposite to the input to the coil L, neglecting impedance losses. The anode of the diode 64 is grounded through an integrating filter comprising a variable resistor 65 and a capacitor a. parallel connected having a value equal to the filter 62 to insure equal degrees of filtration in the output of the diodes SI and 64. The resistor is connected to one pole of a three pole, three position switch 55. This switch is shown in the position in which the filter 5a is grounded and is used for a calibration purpose to be described more fully hereinafter. The cathode of the diode 6| and the variable point of resistance of the resistor 65 are joined by a pair of equal resistors 68 and 69. When properly calibrated, the voltage at the junction of 58 and 69 is zero during the bar period of a standard armature coil. The voltage across the resistor 69 is steady and of opposite polarity to voltage 63 as indicated by the voltage line 61 in Figure 5. The family of voltages indicated by the reference character 10 in Figure 5 are typical plots of the voltage between the junction of the resistors 68 and 69 and ground during normal operating conditions. If an armature condition other than normal obtains, the filtering combination 62 and 55-55:; will not balance perfectly and for this reason, an additional grounded filtering condenser l! is connected to the junction point of the resistors 68 and 69 to insure that the voltage in will be a nearly steady D. C. voltage of polarity and magnitude deter mined by the value of the voltage 63. A normally open switch '12 is connected in shunt with the condenser 1| for calibration purposes to be described more fully hereinafter. The junction point of the resistors 68 and BS is also connected to the control grid of a keyed amplifier 13.

Before proceeding further with the shaper unit, it is desirable to digress and describe the timing unit in detail. The primary function of the timing unit is to identify a time instant closely associated with the time indicated at 231 very positively. The reference 151 is used herein to designate this time instant associated with time h as they are usually identical and almost coincidental at all events. In the voltage charts of Figures 4 to 8, this time is shown as being identified by a very sharp volage change. This is an idealized condition as transients almost certainly will occur at the beginning of each bar period of operation. The prods may bounce and momentarily make and break contact one or more times, producing a series of sharp voltage changes at approximately this time. In addition, under open circuit conditions, for example, the magnitude of the voltage change or changes at time h may be very small.

In order to secure positive identification of the time 151, the negative half of the prod signal is diverted from the shaper 3! to the timer 33 by connecting the anode of the diode 653 to ground through serially connected resistor Ti and condenser !8 which form an integrating filter. The anode to ground voltage of the diode 6c is repre sented by line T6 of Figure 6. The junction of the condenser 18 and resistor "H is connected to the grid of the squaring and amplifying triode 19 having a grounded cathode and an anode connected to the plus 390R service through load limiting resistor 38. The output or the triode i2 is applied across a filter consisting of the condenser 31 and resistor 82 having a time constant such that it tends to square the output of the amplifier "9. The voltage variation across the resistor 82 is referenced to ground by the diode 33 so that only positive excursions of the voltage across the resistor 82 are applied to the resistor 8 which connects to the grid of a second amplifying triode 85. The anode of the triode 85 is connected to the plus 396R service through a load limiting resistor 86 and the cathode is connected to a voltage divider 3i connected be tween the plus 309R service and ground so as to place a fixed bias, 8 volts for example, upon the triode B5. The voltage applied to the grid of the triode 85 will have a peak amplitude of the order of 20 to 35 volts and the 8-volt bias placed on the cathode insures that this tube will be saturated during any period in which the input voltage thereof exceeds 8 volts thus affecting a further squaring action on the input wave form. The output of the amplifier 85 is developed across the series connected condenser 38 and the re sis-tor 39 to affect a further squaring action thereon. The voltage across the resistor 89 is referenced to ground by the diode 9i and is applied to the grid of a triode 99. The anode of the triode is connected to the plus some service through a load limiting resistor 92 and the cathode is grounded. The output voltage between the anode of the triode S and ground is represented by the voltage 83 of Figure 6, which has a very square form and has now produced a fair identification of the instants t4 and 151. The amplifier 9) is saturated from instants ii to 1 and is cut off from 731 to t4 to produce the square wave form 93; that is, the repeated squaring of the input voltage to the timer, amplification of the minimum amplitude portions thereof and discarding of maximum amplitude portions thereof has produced the wave form 93 which is substantially independent of the voltage variations of wave form is due to varying armature conditions well as sharply associated with the instants ii to 4.

The apparatus also includes a source of negative voltage identified here as minus seen, mean volts negative regulated. The anode of t e amplifier 538 is connected to the minus 3MB .5 through the condenser 94 and resistor 95. The junction of the condenser 9 and resistor 85 is connected to the control grid of the first stage of a delay multi-vibrator. Due to the differentiating action of the filters 9d and 95, the voltage has a constant negative I). C. bias with sharp positive and negative going peaks at the 10 times 751 and t4, respectively, as shown at 91 in Figure 6.

The multi-vibrator includes the triode tubes 96 and 98 having their anodes coupled through resistors 9s and N36 with the junction points grounded. The cathodes of these tubes are coupled together and to the minus 3MB service through a load limiting resistor Iii]. The anode of tube 96 is connected to the junction points of the cathodes of the multi-vibrator through the series connected condenser 102 and resistor Hlla. The junction point of the resistor lilla and condenser l'i! is also connected to the control grid of the tube 98. The bias on the grid of the tube at, as represented by the wave form 97, is normally highly negative and maintains this tube cut off, whereas the tube 98 is saturated. As each positive going spike on the wave form 91 hits the grid of the tube 95, this tube is triggered into conduction resulting in a very sudden voltage drop across the resistor 99 which is reflected in amplified form across the resistor I e I, driving the grid of the tube 93 suddenly negative well below the cut off value. When this occurs, the tube 98 shifts suddenly from saturated operation to cut off operation and tube as begins to conduct at some value below saturation. As the apparatus stabilizes, the voltage across the resistor Hll decays at a rate determined by the time constant of the combination of the resistor-condenser I E] Ia and I52 until the grid of the tube 98 reaches out off value at which point the multi-vibrator reverts to its initial state in which it remains until the grid of the tube 96 is again triggered by a positive going spike on the wave form 91. The output of the delayed multi-vibrator, the potential of the anode of the tube 98 to ground, is represented by the wave form I 63 of Figure 6; that is, the tube 93 is cut off from instants 151 to 752 and is aturated from instant ii to instant h. The time duration of ii to rig is determined by the time constant of the resistor-condenser combination i0 is and I92 and must be chosen in reference to the number of bars on the test armature and the rate of rotation thereof to place the instant t2 at some point approaching a mid-bar period at a time during which the prod signal may reasonably be assumed to be free of transients introduced by connection or disconnection of the prods to the particular commutator bar and bouncing of the prods introduced by riding over commutator insulating segments. The instant t2 determines the initiation of the sampling period during which time the prod signal, after comparison with the standard reference level introduced through the triode 64 in the shaper 3i is actually measured to determine armature conditions. The duration of the sampling period is determined by a sampling multi-vibrator which consists of triodes I04 and H 5 which are anode-coupled through resistors I66 and H31, respectively, with the junction of the two resistors grounded. The cathodes of the tubes 1 at and i are connected together and are connected to the minus 3MB service thru the resistor Hi8 and through position switch Hi9 which is preferably mechanically connected to switch 66 to be operated therewith. The grid of the tube I5 3 is connected to the minus 396R service through the switch Hi9 and resistor l Iii. A condenser IH and resistor H2 are series connected across the cathode and anode of tube 1 E4 and the junction of the resistor-condenser connects to the grid of the tube [95. The resistor Hi6 and condenser !!3 form a filter which applies a sharp negative voltage spike at the instant t2 to the anode of tube I04 and condenser I I I as shown by the dashed line lfita of Figure 6'. The thus differentiated voltage IE3 is utilized to trigger the sampling multi-vibrator. The positive going volttage spike which would normally be expected at instant h is absorbed by a clipper diode HA. In the normal, stable state of the sampling multivibrator, the tube I is saturated and the tube IE4 is out off. Under normal conditions, the grid of the tube I04 is maintained at minus 300 volts and the cathode is positive with respect to this voltage by the voltage across the resistor I138. The negative going spike in the voltage Nita momentarily depresses the plate voltage on the tube I534 and discharges the condenser III sufiiciently to drive the grid of the tube I05 below the cut off value, with the result that the negative grid to cathode of the tube IE4 is removed and the tube conducts momentarily. After cut off at time t2, the potential of the grid of the tube m5 decays exponentially back to the cut off value at which time the sampling multi-vibrator reverts to its stable state. The time between out off of the tube I05 and return thereof to conduction is determined by the time constant of the filter combination of the condenser H I and resistor H2. This time constant is preferably much shorter than the time constant of the delay multi-vibrator and is utilized only to determine the short duration of the sampling period, during which time the prod signal is actually acted upon to determine armature coil condition. The output of the sampling multi-vibratpr is developed across the resistor I9! and is represented by the wave form H5 of Figure 6, which shows that the tube I95 is saturated except for the short out off time period t2 to is.

The anode of the tube I65 is connected to the suppressor grid of the keyed amplifier 73 of the shaper unit 31. The anode of the shaper unit of the keyed amplifier I3 is connected to the plus 300 volt service through the current limitingresistor H8 and one pole of the switching mechanism E6. In the position of the switch illustrated in Figure 2, the resistor H6 is connected to the plus 3MB, service. A voltage divider II'I consisting of a group of series connected resistors having two variable units is connected between the plus 3093 service line and ground. The screen grid of the amplifier i3 is connected through a resistor H8 to one of the variable resistors of the voltage divider I I1 and the cathode of the keyed amplifier is connected to the other variable resistor of the voltage divider II'I. lhe potentials of the cathode and screen grid are adjusted to maintain the keyed amplifier it cut oif except when the suppressor grid is at ground potential. The very square shape of voltage i I5 insures that the suppressor grid will maintain the tube I3 cut of]? until instant t2 when the suppressor grid potential is reduced to ground and will again out ofi tube 13 at instant is when the suppressor grid is again suddenly driven negative below cut-off value.

At the instant t2, when the suppressor grid suddently reaches ground potential, the keyed am" plifier is placed under the effective control of the combined output voltages of the reference diode 64 and diode SI which is represented by voltage '10 of Figure 5. During cut-off periods of the keyed amplifier 13, the condenser I29, which is connected to the cathode of the keyed amplifier and through the resistor I2I and clamping diode I22 to ground, accumulates a substantial charge through the resistor H6. As soon as the keyed amplifier begins to conduct, plate current is supplied to the amplifier through the resistor 4 I6 from the plus 300R service and from the condenser I2il until the circuit stabilizes after which steady plate current is drawn from the plus 300 service alone. The duration of the sampling period, that is, ie to t3, must be sufficient to insure the attainment of this stable operating condition as conduction ceases at time 153 and the sampling period is terminated. The stable level of plate to ground voltage of the tube I3, represented by voltage I26 in Figure 5, during the sampling period is determined solely by the voltage input level on the control grid from the di odes 6| and 64. Consequently, the charge, voltage across the condenser at each instant i2 is determined by the level of voltage 10 during the sampling period. At instant t3, the total voltage available to produce current flow through resistors H6 and IZI is 300 minus the voltage across the condenser I26 or the final voltage drop across resistor H6 in the preceding sampling pe riod and the voltage across resistor I2I is a function of the voltage across H6 which is represented by voltage waves I25 in Figure 5.

The voltage I25 is characterized by a sharp peak at the time is which decays exponentially to the next succeeding time is. The voltage IE5 is applied to the grid of a stiffener triode or cathode follower IZt, having the anode thereof connected directly to the plus 300R service and the cathode thereof grounded through a resistor I21 across which the output voltage of the shaper unit 3! is developed. The wave form 125 also qualitatively represents the output voltage of the stiffener I25 and is the voltage which is applied to the alarm and detecting units to be described.

The shaper 3| is calibrated as follows: Switches 9a and 4411 are opened to prevent motor rotation and actuation of the alarms. The switch I3a is actuated to closed position to release the brake I I. An armature having a standardized coil is then placed in the bearing support 4 and rotated to place the standardized coil in prod position, after which the arm 29 is lowered, care being taken to insure that the prods engage the commutator bars connected to the standardized coil. The switches 66 and I63 are then thrown to the mid-position which grounds the filter 65 through the meter I28 and removes bias voltage from the sampling multi-vibrator. The potentiometer IIa is next adjusted until a full scale deflection of the meter is obtained which will correspond to approximately a 10-volt drop across the resistor 65. The adjusting arm of the adjustable resistor 65 is then looked in the midposition to give a voltage at the junction of the points 58 and 69 of approximately plus 5 volts. The switches 66 and I09 are next actuated to the right hand position as shown in Figure 2 which places the meter I28 in the plate circuit of the amplifier I3 and maintains the multi-vibrator in inactive condition. Almost immediately following disconnection of the minus 300 service to the multi-vibrator, the suppressor grid of the keyed amplifier I3 assumes ground potential which is the condition occurring during a sampling period. The switch 12 is then closed to place the control grid of the keyed amplifier at ground potential. The adjustable portions of the volta e divider II'I are next adjusted to vary the potential on the screen grid and cathode of the keyed amplifier until the meter I 28 has approximately half scale deflection. The switch I2 is now opened and the resistor 57 in the prod amplifier output circuit adjusted until the meter again reads half scale, indicating that the output of the prod diode BI is exactly equal and opposite to the output of the referencing diode 64, and that the control grid of the keyed amplifier is at ground potential. At this time, the switch I2 may be opened and closed and a failure of this action to alter the deflection of the meter I 23 is a check on the calibration. The calibration procedur is now complete and the switches Ifiii and 66 are actuated to restore service to the multi-vibrator and to remove the meter I 28 from circuit. Switch I3a is opened and switch 44a is closed to restore the apparatus to operating condition.

Referring now to Figure 3, the open circuit and deficient turn detectors, 3! and 38, respectively, and the open circuit, deficient turns, surplus turns and incorrect connection alarms, 39, 4Q, 35 and 36, respectively, are shown as a single figure, the separate units being segregated by dashed lines. The output signal of the shaper is applied to the unit of Figure 3 by the conductor I38 connected to the cathode of the stiifener triode I26.

Detection of S-T or 1-0 conditions is relatively simple as these conditions are represented by peak values of the voltage I25 above a predetermined value without particular concern with a time reference.

The 1-0 alarm 33 is activated from the shaper by connecting the control grid of the I-C thyratron I32 to the conductor I36 through a grid current limiting resistor I33. The screen grid and cathode of the thyratron are connected to the plus 300 service through a voltage dividing resistor bank I34 to maintain the cathode and screen grid at a previously determined potential to be produced in the shaper output by an incorrect connection which will insure that the thyratron I32 will not fire unless the signal applied to the control grid indicates the presence of an incorrect connection. The anode of the thyratron I32 connects to a serially connected current limiting resistor I35, relay coil I36 to the manual plate voltage supply control switch 44a. A filtering condenser I3! is connected between the plate voltage supply line and ground to protect the alarm from transient voltage conditions. The relay 53E switches 28 and 133 when energized to stop the motor 3 and set the brake II to discontinue testing operating and to remove plate voltage from the other fault alarms.

Switch I33 a double throw switch and energizes an 1-0 neon glow fault lamp I39 when actuated by the relay coil to open the plate voltage supply to the remaining alarm system. Energization of the lamp I39 indicates the existence of an incorrect connection in a test armature.

The S-T fault alarm 35 is similar in all respects to the I-C alarm just described and corresponding parts are given the same reference characters distinguished by the addition of a prime. The screen grid and cathode of the S-T alarm thyra tron I 32 are connected to the voltage divider I 34 to bias the thyratron I32 to a lower value than the static bias on the thyratron I32. The value of the bias on the thyratron I32 is the upper limit of the shaper output voltage produced by an acceptable armature. Consequently, a peak voltage on the wave I25 indicating an S-T condition will not bias the thyratron I32 into conduction but will bias the thyratron I32 into conduction, resulting in energization of the relay I35 to open switches 2| and I 38 which stops the test, removes plate voltage from the 0-0 and D-T alarms, and energizes the S-T signal lamp I39. In this connection, it is to be noted that a peak voltage value indicating an 1-0 condition in a test armature is sufiicient to render the thyratron I32 conductive; however, the thyratron I 32 will fire simutlaneously and actuate switch I38 to remove plate voltage from the S-T alarm system, thus preventing false alarm indication.

Distinguishing between 0-0 and D-T faults is more complicated than distinguishing S-T and 1-0 faults because the former two conditions are evidenced by failure of the voltage I to reach a particular value at a determined time.

The O-C detector 31 is activated by the output voltage signal I25 from the shaper unit which is applied through the conductor I and current limiting resistor I40 to the grid of a triode gate tube MI. The cathode of the gate tube MI is connected to a voltage divider I42 which is connected between the plus 300 service and ground to establish a static bias level on the gate MI. The bias on the cathode of the tube MI is such that the tube remains cut-01f as long as the signal applied to the grid is below the value previously determined as the maximum produced in the shaper output by an open circuited armature coil. Any signal voltage exceeding the maximum O-C value of the shaper output triggers the gate tube I4I into conduction. The anode of the tube I 4| is connected to the 300 service through a current limiting resistor I43. The output of the triode I4I, as represented by variation of the anode to ground voltage thereof is indicated by the line I44 of Figure 7. It is to be noted, in this connection, that an open circuit condition does not cause an alteration in plate voltage of this tube; hence the plate voltage for this condition is a straight line at plus 300 volts. Signals applied to the grid of this tube representing D-T, normal, S-T or 1-0 conditions trigger the tube into conduction. A voltage signal at this point representing a normal D-T condition may or may not trigger the gate tube to the saturation point, though it is so indicated in Figure 7. The anode and cathode of the tube I4I are connected by the serially connected condenser I45 and resistor I46 with the junction thereof connected to the grid of an inverter tube I41. The cathode of the tube I 41 is maintained at the same potential as the cathode of the tube I4! and the anode is connected to the plus 300 service through a. current limiting resistor I48. The grid to cathode voltage of the inverter I4: is represented by the wave form I49 of Figure 7 which is characterized by sharp negative going spikes for all conditions other than open circuit or gross deficiency of turns. The anode voltage of the tube I41 varies between saturation and cut-off conditions depending upon the value of voltage I49. For open circuit conditions, voltage I49 is steady and the inverter I41 remains saturated. The negative going spikes produced by conditions other than open circuit cut off tube I47 causing plate to ground voltage conditions represented by the voltage I5t of Figure 7. The output of tube I4! is developed between the plate and the minus 300 service through serially connected condenser I5I and resistor I52. The junction point of the condenser I5I and resistor I52 is connected through a current limiting resistor I 53 to the control grid of a saw-soothing thyratron I54. The

difierentiating eifect of the condenser I 5| and.

:mum value i E: resistor I52 produces a voltage form represented 'by I 55 of Figure '7 characterized by a sharp positive going spike at time is for all operating con ditions except open circuit, even though the maxiof the positive going spike is negative with respect to ground. The screen grid and cathode of the thyratron I54 are biased negative by being connected to the voltage divider 55: extending between the minus 300 service and ground. The positive going spikes on the voltage I55 reduce the control grid to cathode voltage of the thyratron E54 below the firing point and the tube will fire for all conditions other than open circuit or gross deficiency of turns. The anode of the thyratron Hid is connected to a current limiting resistor l? which is proportioned to allow plate current within the tube rating. The resistor i5"! connects to a condenser which is connected to the cathode of the tube I54. The resistor I5? also connects to a switch I59 arranged selectively to be connected to any one of a plurality of resistors I68 in turn connected to the plus 300 service. Relative voltage levels are open circuit detector unit. assumed herein, the negative bias on the cathode of the gate tube is! determined by the setting of the voltage dividing bank M2 determines the setting of the gate tube or the minimum amplitude of voltage I which will trigger the gate tube into conduction. This value, for example, may be '75 volts positive which will establish a boundary level between the formal open circuit and deficient turn output level of the shaper unit. The steady state level of and the voltage divider bani: negative bias of, for example, minus on the cathode of the thyratron IE4. positive value of voltage I55, which reduces thyratron grid to cathode voltage below off value, minus three and a half volts for example, will trigger the thyratron into conduction, or a peak amplitude of the positive spike on the wave form of 50.5 volts above the base level.

important in the 56 maintains a 246 volts Thus, any the The cascaded gate and inverter may be assumed to have an amplification value of at least 100. Therefore, any value of voltage IZE, which reduces the negative grid to cathode voltage of the gate tube Hi! approximately .55 volt below cutoff value, will actuate the open circuit detector.

If it be assumed that the gate tube is provided with a '75 volt bias and has a negative grid to cathode cut-off voltage value of 13, the minimum peak amplitude of voltage I25, which will just trigger the tube MI into conduction, is 62.55 volts which establishes the boundary between 0-6 and D-T conditions. Due to the amplification factor, halving the effective amplification, for example, would increase the minimum thyratron triggering voltage and it appears in voltage !25 to 63.10 volts; that is, the detector channel arrangement just described provides sharp differentiation between 0-0 and D-T conditions rather independently of exact amplification in the gate and inverter stages;

During any extensive period of non-conduction of the thyratron, the condenser I58 acquires a charge by current flow through one of the resistors I56 from the plus 300 service. When the thyraton 54 is triggered into conduction, the plate current permitted by the resistor is much greater than the current which can be drawn through the resistor 66. Consequently,v

plate current is drawn from the condenser "I58 which gradually lowers the anode voltage below Under the conditions voltage I55 is minus 300 the cutthe ionization value, ten volts for example, causing the tube to cease conduction with an instantaneous anode voltage on the thyratron of minus 236 volts, assuming that the cathode is maintained at 246 by the voltage divider I56. The time constant of the condenser I58 and resistor must be closely correlated to the prod frequency of the test armature; that is, this time constant must be great enough to prevent the anode voltage of the thyratron from increasing from its minus 236 value to ground potential in the interval between succeeding time periods identified as is and must permit the anode voltage to decay to ground potential in a time period which is less than twice the time interval between succeeding time periods identified as is. The plurality of resistors I63 are provided for the purpose of changing this time constant in order to accommodate the apparatus for testing armatures having varying numbers of commutator bars.

The output voltage of the open circuit detector 31 and deficient turn detector 33 is plotted in Figure 8, the two voltage conditions being identified by 0-0 and D-T, respectively. Each time the thyratron I54 fires at a time is, which means that the particular coil under test is not subject to open circuit, the 0-0 voltage wave is driven sharply negative to the minus 236 value and begins to decay in a positive direction in the ensuing time interval. When the next time interval t3 arrives, the voltage on the anode of the thyratron IEfl will still be well below ground and will again be driven to its maximum negative value if the thyratron fires on the next instant t3. If the thyratron should not fire on the next instant is, indicative of an O-C condition in the coil under test, the anode voltage of the thyratron l54 will continue to decay in accordance with the dashed line to ground potential, or shortly following time is.

The output voltage of the thyratron I54 is applied directly to the control grid of the 0-0 alarm thyratron I63. The cathode of this thyratron is grounded through a current limiting resistor I10 and the screen grid is directly grounded. The anode of the thyratron I63 connects to the 300 service supply from switch Ma through a current limiting resistor IBI and relay coil I62. The thyratron I63 is of the type which will begin conducting when the grid thereof substantially reaches ground potential. At any instant is at which the thyratron I55 fails to fire, the anode voltage thereof will decay to ground shortly thereafter thyratron IE3 will fire and draw plate current through the relay I62. The relay I62 actuates switch 23 to de-energize the drive motor and switch I64 to remove plate current from the D-T alarm ii]. A neon glow signal lamp IE5 is connected to be actuated by the voltage drop through the resistor E5! to provide a visual indication of the presence of an O-C or gross D-T condition in the coil under test.

The open circuit detector is provided with a current limiting diode I66 having its cathode connected to the voltage divider I52 to maintain a positive bias of approximately 50 volts thereon in order to limit peak values of output voltage from the thyratron I54 for a purpose described hereinafter.

The presence of more than one open circuited armature coil is a rare but occasionally encountered condition called multiple 0-0. If the test armature is subject to multiple 0-0, the prod signal will be zero when the first open circuit i7 coil is in prod position because the high and low impedance paths through the armature between the prod bars will each be open circuited. Such a prod signal will not produce a sampling period in the timer 33 and the shaper output will be at ground potential. The O-C alarm will fire, however, because there will be no signal input to the -0 detector operating to prevent O-C detector output voltage from decaying to ground potential at time t; and energizing the 0-0 alarm. In this special case, the O-C alarm will be given by the first of the open circuited armature coils to reach prod position, but there will be no indication of the location of the other open circuit armature coil.

The deficient turn detector 38 is identical with the open circuit detector 31 except that it does not require the protector diode I66 and the volt age biases are different. Those parts of the deficient turn detector which are identical with corresponding parts of the open circuit detector are identified by the same reference characters distinguished by the addition of a prime. The positive bias on D-T gate tube I4! will be set at 100 volts, for example, so that a peak value of voltage I25, which will just fire the open circuit detector 31, thus preventing O-C alarm, Will fail to fire the DT gate tube Mi, which will ultimately result in a failure of the thyratron 55:3 to fire and allow the cathode to ground voltage of the thyratron I54 to decay to ground potential. The condenser I58 and resistor I60 combination has a time constant which is slightly longer than the time constant of condenser I58 and resistor IEO as is shown by the comparative plots of the O-C and D-T voltages in Figure 8. It is to be observed also that a peak amplitude of voltage I25 insufficient to actuate the open circuit detector 31 will also be insufficient to actuate the D-I detector 38. However, under this condition, representing an actual open circuit in the coil undergoing test, the 0-0 alarm thyratron I63 will fire first because of the more rapid rate of decay of anode voltage for the thyratron I54 than for the thyratron 554'. Once thyratron I63 is fired, relay I62 removes plate voltage from the D-T alarm and prevents firing of that alarm regardless of the voltage on the anode of the thyratron I54.

The output voltage of the anode of the thyratron 54' is applied to the control grid of a thyratron I 6? which has its anode and screen grid connected through the resistor lid to ground. The anode of the thyratron It? is connected to the 300 volt service controlled by switch 44a through a relay coil E68 and a current limiting resistor N59. The D-T alarm neon lamp III is connected across the resistor I69 to be operated by the voltage drop therein when thyratron i6? fires. Once the D-T alarm thyratron I6? fires, the voltage drop through the resistor I75 places such a positive bias on the cathode of the thyratron I53 that a peak amplitude voltage of approximately 126 volts positive, for example, would be required on the plate of the thyratron I54 to fire thyratron i 66. Since the limiter diode I65 is set to limit positive plate voltage on the thyratron I54 to a value not exceeding 50 volts, for example, firing of the thyratron I 81 positively prevents subsequent firing of thyratron I63, which would give a false O-C indication.

With reference to the operation of the D-T detector 38, the various voltage plots of Figure 7 labelled O-C represent the corresponding voltage condition in the D-T detector 38 upon occur- 18 rence of an actual D-T condition indicated by failure of the tube It! to be triggered into conduction.

With respect to S-T and 1-0 faults, the period between first contact of the prods with a bar connected to such a faulty coiland firing of the proper alarm is equal to the delay period 751 to E and the sampling period 2 to 733. The sum of this is usually approximately half a total bar period. Consequently, the braking structure is made very quick-acting, the armature will be stopped with the prods engaging the commutator bars connected to the faulty coil and thus it not only indicates the nature of the fault but locates the particular coil containing it.

With respect to O-C and D-T faults, however, the period between the first prod contact with the bars connected to the faulty coil and the firing of the alarm is equal to the delay period it to t2, the sampling period it to ts, plus the voltage decay period following the fault period t: to tx or t as the case may be, as indicated in Figure 8. Following this, the armature will stop within a time period determined by the brake. Since the time t; to ix must be great enough to be unaffected adversely by varying periods between succeeding t3 instants due to inequalities in communtator bar spacing and the time is to t' must be greater than the time ta to tx to allow a proper hold-01f between firing of the 0-6 alarm and firing or the D-T thyratron, the armature may stop with the prods engaging the bars connected to the faulty coil or the next pair of communicator bars. In any event, this factor can be determined for any particular armature type under test and the prod bars of the preceding pair of commutator bars marked to indicate the faulty coil in such action is desired for precise study of fault conditions.

The present arrangement is such that an actual S-T condition will fire only the alarm thyratron it? which will immediately remove plate voltage from the 0-0 and 13-1 alarm systems. An actual I-C condition will fire thyratron I32 and I 82, tending to give a false S-T indication. However, firing of the thyratron I32 removes plate voltage from all other alarms and prevents a false indication being registered. Similarly, an actual O-C condition will tend to fire both alarms I63 and I61. However, the difference in time periods of the output filters of the 0-0 and D-T detectors will insure that the 0-0 alarm thyratron I63 will fire first, which will immediately remove plate voltage from the 10-1 alarm and prevent false indication thereof. In case of an actual D-T condition, the firing of thyratron I6? places a static bias on the thyratron 483 of a value which is greater than the maximum grid potential permitted to be applied to the thyratron I63 by the limiter diode it, thus preventing false O-C indications.

Cathode heaters have been omitted from Figures 2 and 3 for clarity of illustration. lhe cathode heaters for the various tubes may be energized by conventional means and subjected to fixed D. C. bias by conventional means where this is desirable to avoid high heater to cathode potentials.

The test apparatus disclosed herein is particularly reliable from a calibration standpoint since calibration is accomplished by adjusting the voltage 70 to ground potential which is a value which can always be reliably reproduced. The gating level of the I-C and S-T alarms systems are readily adjusted by means of the variable resistors I34 and 534 while the signal level introduced from the shaper unit 3! with a standardized armature coil in prod position is adjusted by means of the variable resistors 51 to simulate a particular fault. Similarly, the gating level of the O-C and 13-1 detectors are adjusted under similar conditions by adjusting the variable resistors I42 and H52 with the resistor El or $5 adjusted to simulate particular faults.

Referring particularly to the representation of voltage !25 in Figure 5, the line marked OC represents the boundary between armatures which are classed as 0-0 and those classified as D-T. The lines marked D-T and S-T are boundaries of armatures which will be accepted as normal and are determined by the outer limits of this voltage [25 produced by normal armatures. The line marked N is a standardized reference point. Similarly, the line marked 8-5? is the lower limit of voltage L25 produced by armatures which are marked ST. The line I-C is the lower limit of the voltage :25 produced by armatures which will be considered open circuits-d. By the adjusting procedures just described, the voltage response levels can be adjusted to widen or narrow the limits of acceptable armatures and to adjust the alarms to respond to voltage levels which will truly represent particular fault conditions. In ordinary production usage, the nature of a fault indicated by the tester is not particularly material because the armature will be rejected for salvage in any event. However, for testing purposes to determine the location of faulty operations in production procedures, the nature of the fault discovered is of considerable importance and can be recorded in any suitable manner on a statistical basis if the number of rejects approaches a value indicating that improvement in production procedures is necessary.

Since the signal, which is actually utilized to determine armature coil conditions, is a result of a balance between two voltages, each of which emanates from the A-F generator ll, variations in the output of this element does not efiect the efficacy or sensitivity of the test unit within rather wide limits.

The apparatus described herein has been found to be highly reliable and accurate in operation and to subject production line armatures to the desired series of tests at very low cost and in very short periods of time. The foregoing is particularly desirable because certain types of the faults detected by this apparatus may not be detected even when the motor is given a preliminary run in and will not appear until the motor is subjected to an overload or to a continuous period of operation, resulting in damage not only to the faulty armature but to other elements to which it is mechanically or electrically connected.

While the invention has been illustrated and described in detail herein, it is not to be limited thereto but various changes may be made in the construction, design and arrangement of parts without departing from the spirit of the invention or the scope of the appended claims.

I claim:

1. Armature testing apparatus comprising means for generating a magnetic field, means for rotating an armature to be tested in said magnetic field, a pair of contact members positioned to engage adjacent bars on the commutator of a test armature to pick up the voltage induced in each armature coil as it moves into a predetermined position, a plurality of signal alarms, means for measuring the voltage between said contacts as each armature coil moves to said predetermined position and for selectively energizing said alarms in accord with the voltage between said contacts if such voltage is without a predetermined range.

2. Armature test apparatus comprising means for generating a magnetic field, means for rotating an armature to be tested in said magnetic field, a pair of contacts adapted to engage the commutator of a test armature and to establish an electrical connection to each coil of a test armature as each such coil moves into a predetermined position in said magnetic field, means governed by the voltage between said contacts for enerating a signal which varies in voltage level with variations in voltage level between said contacts, means for discarding all portions of said signal except the portion thereof derived from the potential between said contacts while said contacts engage a predetermined portion of each pair of commutator bars on a test armature, a plurality of alarm signals, and means for selectively actuating said alarm signals from the retained portion of said signal according to deviations of said signal from a pre etermined range of voltage levels.

3. Apparatus according to claim 2 including means actuated by said alarm signal actuating means for stopping said armature rotating means when an alarm is actuated.

4. Armature test apparatus comprising means for generating a magnetic field, means for rotating an armature to be tested in said magnetic field, a pair of contacts adapted to engage the commutator of a test armature and to establish an electrical connection to each coil of a test armature as each such coil moves into a predetermined position in said magnetic field, means governed by the voltage between said contacts for generating a signal which varies in voltage level with variations in voltage level between said contacts, means for determining and fixing the time of first contact between said contacts and a connected pair of commutator bars independently of the rotational speed of a test armature for generating a second signal having a predetermined time lag with respect to such time of first contact and a time duration which is less than the remaining time of contact between said contacts and said connected pair of commutator bars, means normally blocking said first mentioned signal and actuated by said second signal to transmit that portion of said first mentioned signal which coincides in time with said second signal, a plurality of alarm signals and means activated by said transmitted portion of iirst mentioned signal for selectively energizing said alarms according to deviations of said transmitted signal from a predetermined value.

5. Armature testing apparatus comprising means for rotating an armature to be tested, a source of current having a frequency per unit of time which is large compared to the frequency with which individual coils on a test armature are rotated by a fixed point per unit of time, means energized from said current source for generating a magnetic field linking a test armature driven by said rotating means, a pair of contacts positioned to engage commutator bars connected to opposite ends of individual coils on a test armature, means for deriving a first signal from said pair of contacts which is proportional to the voltage therebetween as each coil on a test armature is connected to said contacts, means for deriving a second signal from said current source having opposite polarity to said first signal and a value such that the sum of said second signal and the first signal produced by a standard normal armature coil is zero, means for deriving a third signal from said voltage between said contacts appearing in time delayed relation to the appearance of coil voltage between said contacts and terminating before the termination of such coil voltage between said contacts, and means for producing a fourth signal which is proportional to the sum of said first and second signals, means blocking operation of said fourth signal producing means except during the time said third signal is produced, a plurality of alarms, and means for energizing said alarms selectively in accord with deviations of said fourth signal from a predetermined range of values.

6. Armature testing apparatus comprising means for subjecting the coils of a test armature to a magnetic field of predetermined value, means for successively generating a signal proportional to the voltage induced in each coil of a test armature, a plurality of alarms, means for energizing certain of said alarms selectively according to the degree by which said signal exceeds a predetermined value, and means for energizing certain other of said alarms according to the degree by which said signal falls below said predetermined value.

'4, Armature testing apparatus comprising means for subjecting the coils of a test armature to a magnetic field of predetermined value, means for successively generating a signal proportional to the voltage introduced in each coil of a test armature, a first alarm, a thyratron controlling the energization of said first alarm having a grid connected to receive said signal and biased to nonconducticn unless said signal exceeds a first predetermined value, a second alarm, a thyratron controlling the energization of said second alarm having a grid connected to receive said signal and biased to non-conduction unless said signal exceeds a second predetermined value which is intermediate said first predetermined value and a normal signal value, a third alarm, a third thyratron controlling the energization of said third alarm and having a control grid, means connected to receive said signal and actuated by each successive signal exceeding a, third predetermined value below said normal signal value for applying a bias voltage to said third thyratron grid sufficient to maintain said third thyratron cutoff for a time period exceeding the time period between successive signals, a fourth alarm, a fourth thyratron controlling the energization of said fourth alarm and having a control grid, and means connected to receive said signal and actuated by each successive signal exceeding a predetermined value below said third predetermined value for applying a bias voltage to said fourth thyratron grid sufficient to maintain said fourth thyratron cut-off for a time period exceeding the cut-off time period of said third thyratron.

8. Apparatus according to claim 7 including means energized by said first thyratron for deactivating said third, second and first alarms, means energized by said second thyratron for deactivating said second and first alarms, means energized by said fourth thyratron for de-activating said third alarm and means activated by said third thyratron for de-activating said fourth alarm.

9. Armature testing apparatus comprising means for generating a magnetic field, means for rotating an armature to be tested in said magnetic field, means for generating a signal proportional to the voltage induced in each coil of a test armature as each armature coil moves to a predetermined position in said magnetic field, a first alarm, a thyratron controlling the energization of said first alarm having a grid connected to receive said signal and biased to non-conduction unless said signal exceeds a first predetermined value, a second alarm, a thyratron controlling the energization of said second alarm having a grid connected to receive said signal and biased to non-conduction unless said signal exceeds a second predetermined value which is intermediate said first predetermined value and a normal signal value, a third alarm, a third thyratron controlling the energization of said third alarm and having a control grid, means connected to receive said signal and actuated by each successive signal exceeding a third predetermined value below said normal signal value for applying a bias voltage to said third thyratron grid sufficient to maintain said third thyratron cut-off for a time period exceeding the time period between successive signals, a fourth alarm, a fourth thyratron controlling the energization of said fourth alarm and having a control grid, and means connected to receive said signal and actuated by each successive signal exceeding a predetermined value below said third predetermined value for applying a bias voltage to said fourth thyratron grid sufficient to maintain said fourth thyratron cutoff for a time period exceeding the cut-off time period of said third thyratron, means energized by said first thyratron for de-activating said third, second and first alarms, means energized by said second thyratron for de-activating said second and first alarms, means energized by said fourth thyratron for de-activating said third alarm, means activated by said third thyratron for de-activating said fourth alarm, and means energized by each of said thyratrons when rendered conducting for stopping rotation of a test armature.

l0. Armature testing apparatus comprising means for generating a magnetic field, means for rotating an armature to be tested in said magnetic field, means for generating successive signals each having a voltage proportional to the voltage produced in each coil of a test armature as each armature coil is moved to a predetermined position in said magnetic field, a fault alarm, a thyratron connected to energize said alarm when conducting and having a control grid, a resistor and a condenser connected in series across sources of potential above and below the grid cut-off potential of said thyratron, said thyratron grid being connected to the junction of said condenser and resistor, means actuated by each of said successive signals having a voltage above a predetermined value for driving the voltage of said junction to a negative value below said grid cut-oif value, and said condenser and resistor having a time constant such that the volt age of said junction decays from said negative value to said cut-off value in a time period exceeding the time period between said successive signals.

11. Apparatus according to claim 10 including a second fault alarm, a second thyratron connected to energize said second fault alarm when conducting, a second condenser and a second resistor connected in series across sources of potential above and below the cut-off value of said second thyratron grid, said second thyratron grid being connected to the junction of said second condenser and second resistor, means actuated by each of said successive signals having a voltage above a second predetermined value which is higher than said first mentioned predetermined value for driving the voltage of said second mentioned junction to a negative value below said grid cut-01f value, and said second condenser and second resistor having a time constant such that the voltage of said second mentioned junction decays from said negative value to said cut-off value in a time period exceeding said first mentioned time period.

12. Armature testing apparatus comprising means for rotating an armature to be tested, a source of alternating current having a frequency which is large compared to the frequency with which individual coils on a test armature will be rotated by a fixed point by said rotating means, means energized from said current source for subjecting an armature rotated by said rotating means to a magnetic field, a pair of prods positioned to engage a pair of commutator bars on a test armature connected to opposite ends of individual armature coils as each such coil is rotated to a predetermined position in said magnetic field, means for comparing that portion of the current in said prods produced by the voltage induced in the coils of a test armature as each such coil assumes a predetermined position in said field having one polarity to a current of opposite polarity derived from said source and having a voltage equal and opposite in polarity to compared prod current produced by a standard armature to produce a difference signal, means actuated by that portion of the current produced in said prods which is opposite in polarity to that portion of prod current used to generate said difference signal for producing a sampling signal during the said portion of the time said prods engage each pair of commutator bars connected to individual coils of a test armature, means actuated by said difference signal and controlled by said sampling signal for producing an alarm signal proportional to said difference signal and initiated in time coincidentally with said sampling signal, and a plurality of alarms selectively actuable by values of said alarm signal differing from a predetermined normal range of values of said alarm signal.

13. Armature testing apparatus comprising electrically energized means for rotating an armature to be tested, a field structure positioned to embrace an armature driven by said rotating means, a winding on said field structure, means for energizing said winding, a pair of prods for engaging the commutator of an armature to be tested, means mounting said prods for movement to and from commentator engaging position, a plurality of fault alarms, means connected to said prods for selectively energizing said fault alarms according to deviations in the voltage between said prods from a predetermined normal, a brake normally biased to stop said rotating means, electrically actuated means for releasing said brake, means for simultaneously energizing said rotating means and said brake releasing means, and means actuated by each of said fault alarms for de-energizing said brake releasing means and 6) a4 said rotating means whereby the location of a faulty coil is indicated by the position of said prods on the commutator of a test armature.

14. Apparatus according to claim 13 including means actuated by said prod mounting means when positioned to remove said prods from the commutator of a test armature for de-energizing said winding.

15. Apparatus according to claim 13 including manually actuated means for energizing said rotating means and said brake release independently of said fault alarms.

16. Apparatus according to claim 15 including means actuated by said armature rotating means for de-energizing said rotating means and said brake releasing means after a test armature has been rotated to a predetermined degree independently of the position of said prod mounting means.

17. Armature testing apparatus comprising electrically energized means for rotating an armature to be tested, means for subjecting an armature so rotated to a magnetic field, a pair of prods mounted to engage the commutator of a test armature in position to establish connection to the opposite ends of each armature coil as the armature rotates, a plurality of fault alarms, means ior energizing said fault alarms selectively according to deviations of the voltage between said prods from a predetermined range of values, a brake for stopping said rotating means biased to engaged position, electrically energized means for releasing said brake, each of said fault alarms including means for de-energizing said rotating means and said brake release means when each fault alarm is energized.

18. Apparatus according to claim 17 including means actuated by said armature rotating means for de-energizing said rotating means and said brake releasing means after a test armature has been rotated to a predetermined degree.

19. Apparatus according to claim 18 including means actuated by said armature rotating means for rendering said fault alarms inactive when said rotating means is self-de-energized.

20. Armature testing apparatus comprising means for generating a magnetic field, means for rotating an armature to be tested in said magnetic field, means for establishing electrical connection to the coils of a test armature rotating in said field one by one as each coil is rotated to a predetermined position in said field, means for comparing the level of voltage induced in each coil to a standard reference voltage to produce a difference signal, means for discarding all portions of said difference signal except the portion thereof produced in the middle of the time period during which electrical connection to each coil is established, a plurality of alarm mechanisms, and means for selectively energizing said alarm mechanisms according to the difference between said reference voltage and said induced voltage.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 2,411,848 Camras Dec. 3, 1946 2,427,672 Haydock Sept. 23, 1947 2,606,231 Katzman Aug. 3, 1952 

